Professional Documents
Culture Documents
M Jaykumar
16/04/2010
M Jaykumar
2007
Vacon 10, the first product of the third generation product range launched.
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M Jaykumar
Vacon in brief
Vacon is driven by a passion to design, manufacture and sell only the best AC drives on the planet and nothing else. AC drives can be used to control electric motors or to help generate power from renewable sources. R&D and production units in Finland, the United States, China and Italy, and sales offices in 27 countries. In 2009, Vacon had revenues of EUR 293.2 million and globally employed ca 1,200 people. Vacon's shares (VAC1V) are listed on the Helsinki Stock Exchange.
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Energy-saving technologies
We are more and more dependent on electricity. It is estimated that the energy consumption will increase by 50% between the years 20052030. The consumption of electricity is estimated to double at the same time. 65% of the electricity is produced by burning fossil fuels (oil, coal and gas), creating a lot of CO2 emissions. All technologies that are capable of reducing the consumption of electricity are needed. AC drives are one of the technologies that brings energy-saving benefits and helps preventing the climate change
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Finland factory
Capacity: 500,000 units/year
Production area: 17,000 m2 350 persons Products: Production of Mid-, High-End and Mega power range products New product ramp-up
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US factory
Chambersburg, PA, USA
Standard AC drives Manufactures more than 150,000 units
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Italian factory
Naturns, Italy
Electronics design, assembly and testing Custom-made AC drives
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VACON INDIA
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10
HVAC & Water KAM Honeywell & Veolia Jaykumar Marine KAM Metso & L & T Vispute
Divya
Power Nazeer
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Vacon India
Headquartered in Chennai Facilities in Chennai Design & Engineering of Drive Systems Warehouse Training Service Centre Sales & Service Offices in Chenani Delhi, Mumbai, Pune, Ahmedabad, Bhilai, Vizag, Bangalore, Kolkota, Ludhiana, Hyderabad Factory: Bangalore Repair Centre: Chennai, Bangalore Employees:41
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Key customers
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Driven by Drives
Applications, Products & References
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Motor industry
Building industry
Chemical industry
Cement Industry
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Screw Feeders
Apron Feeders
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INDUSTRIAL AC DRIVES
Vacon NXP, air-cooled Vacon NXP, liquid-cooled Vacon NXC, enclosed Common DC bus components up to 0.75 3250 kW 5.5 5300 kW 110 3250 kW 5300 kW
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Vacon NXS
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M Jaykumar
Vacon NXS
Designed for typical heavy industry applications such as conveyors, mixers, pumps and fans Easy to use All in One software package minimized amount of parameters for all demands High performance open loop vector control
208...240 V (3-phase supply) Power range 0.55/0.75 ... 75/90 kW (230 V) IP21, IP54, Nema 1, Nema 12 H, T 380...500 V 0.75/1.1 ... 355/400 kW (400 V) IP21, IP54, Nema 1, Nema 12 H (wall mounted) L (stand alone), T, C 525...690 V 2.2/3... 500/560 kW (690 V) IP21, IP54, Nema 1, Nema 12 L, T
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IP54 IP21
FR4 230V 400V 500V 690V 3 kW 5.5 kW 7.5 kW FR5 7.5 kW 15 kW 18.5 kW FR6 15 kW 30 kW 37 kW 30 kW FR7 30 kW 55 kW 75 kW 45 kW FR8 55 kW 110 kW 132 kW 110 kW FR9 90 kW 160 kW 200 kW 200 kW FR10 250 kW 355 kW 400 kW FR11 400 kW 500 kW 560 kW
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FR11 IP21
400 kW 500 kW 560 kW
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Vacon NXS Everything required for high reliability and flexibility integrated in compact dimensions
All units protected against water drips and mechanical particles (IP21 and IP54) Temperature controlled cooling fan, easy replacement Cooling channel isolated from electronics Robust structure/frame Standard control I/O Option board slots Power terminals High voltage separated from control unit Integrated brake chopper available for all sizes (standard up to 30kW) Integrated EMC filter as standard for both industrial and public networks Integrated AC choke as standard Modular design to fulfill all EMC regulations (Faraday cage)
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Terminal
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 mA 18 19 20 +10V AI1+ AI1-
Programmable
+24 V GND
OPT-A2 Terminal
21 RO1 22 RO1 23 RO1 24 RO2 230 VAC 25 RO2 26 RO2 FAULT Many possibilities RUN Many possibilities
Defaults settings
Programmable
1...10 k
OPT-A3
Floating +24 V GND
Terminal
21 RO1
Defaults settings
Programmable
I/O Ground Multi-step speed select 1 Multi-step speed select 2 Fault reset Common fot DIN4 DIN6 (GND) Output frequency (0-24 mA) AO common (GND) READY, I 50 mA, U 48 VDC Many possibilities Many possibilities Many possibilities 230 VAC Floating N Many possibilities 4-20 mA, 0-10 V Many possibilities PTC 29 TI1input fault no response 26 RO2 28 TI1+ Thermistor Warning, 25 RO2 22 RO1 23 RO1 FAULT Many possibilities RUN Many possibilities
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5 option board slots (A, B, C, D, E) Slots and boards are hardware coded 2 slots occupied by standard I/O
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Card typecode
26
Card slot
A B C D E DI DO DI DO AI mA V AI mA isol AO mA V AO mA isol
I/O signal
RO NO NC RO NO +10 V ref The rm +24 EXT +24 V Pt1 00 42240 VAC inpu t NOTE
1 2 1 1
2 2
1 1
1 1 2)
3 1 1 3 5
Software Modularity
M Jaykumar
Standard
Basic
All-in-One Applications
Minimized amount of parameter settings for all demands
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NX A_PAN
NX G_PAN
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Start-Up Wizard
Common Settings
Ready !!
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FR10-FR12
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FR10 Feature:
FR11 Advantage:
FR12 Easy cabinet design, chokes can be elsewhere No settings needed, ideal for global OEM Space saving, cost efficient Reliabilty: humidity, aggressive gases Reliabilty: humidity, aggressive gases Connections are not limiting cable selections Flexibility in cabinet design
Complete drive modules + AC chokes 380-500V/525-690V 50-60Hz networks Integrated brake chopper (option) Segregated cooling air channel Varnished boards Robust connections (bus-bar type) Integrated or external control part
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FR13-FR14
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2xFI9
FI13
FI14
FI14 3xFI9 4xFI9 FI13 The FR13/14 construction is based on rectifier units and inverter units, the number of rectifier units depends on current rating and 6 pulse or 12pulse
FR13 380-500V 525-690V FR14
1450A 1180A
2150A 2250A
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Other Components
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Input Chokes
206 39
1 1 1
261A
350
1 1 1
460A
238 39
30 15
3 3 3
30 15
3 3 3
150 275
150 275
140 262
120 354
120
120
120
Note ! Tappings Heat 261A 400A 520A 650A Loss: 460W 570W 810W 890W
40 20
497
204 43
3 2
3 2 200
3 2 145 244 0
520A
165
165
650A
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Cabinet Mounting
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43
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=
FRONT END *
*)
INVERTER
INVERTER
INVERTER
BRAKE CHOPPER
= ~
= ~
= ~
R
= ~
R
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FR4
FR6
FR7
FR8
FI9
FI10
FI12
FI13
FI14
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AFE
Active Front End
IGBT Regenerative 1,5-3,6 kHz 1,35x1,1xUs < 5% LCL External Yes
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AFE - Basic
Regenerative low harmonic rectifier module Based on IGBT technology AFE module HW = INU module HW
switching frequency = 3,6 kHz
LCL-filter on line side is necessary No additional line voltage measurement needed AFE-modules can be connected in parallel in order to increase the power
each AFE are working independently, the load sharing is determined by drooping no additional measurement or connection between modules needed redundacy
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M Jaykumar
AFE+INUs
NFE* operation FFE* Regenerative is required 3 3 Low THD level is required Paralleling possibility Redundancy
2 2
AFE*
* alternative
Common DC bus
INU
INU
INU
BCU
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M Jaykumar
AFE Redundancy
Better redundancy can be acheaved if AFE units are connected parallel. A module can be stopped or started in any time.
No additional measurements are needed No communication between modules is needed Different power sizes can be connected parallel
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Fi10 Fi13
Fi10 Fi13
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HOT STANDBY
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HOT STANDBY
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Typical scheme
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1.6 MW
Motor current = 1637A
0.65 MW
Motor current = 726A
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Double Output
Double Output
460 X 4 = 1840A
385 X 2 = 770A
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Mumbai Wadi Wadi Wadi Jamul Madukkarai Mancherial Tikaria Chaibasa Kymore Sindri
Kiln Fan Pump Grate Cooler ID Fan Slurry Pump Kiln Fan Conveyor Various ID Fan
1500kw/690V 355kW 7.5kW 7.5kW 75kW 22kW 132kW (using existing Slip Ring Motor) 110kW 37kW 200kW 45kW
1 4 1 1 1 1 2 1 1 10 1
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2 90 15
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Customer ACC Wadi Power plant ID FD SA PA - 75kW to 355kW 32drives Chamundeswari Sugars ID FD SA PA and BFWP 5.5kW and 75 to 560kW 31nos Department of Atomic Energy FD 250kw 4nos ( 12 Puls trafo & motor) Doodganga Sugars ID FD SA & PA 75kW & 250nos 6nos Himatsinga ID FD SA PA and BFWP ,fuel feeder 5.5kW to 380kW 31nos Hindalco ID and FD 120kW & 160kW 2 no. each Ind Bharat ID FD SA PA and BFWP 410kW to 710kW 21drives (all 12 puls 690V) Kakatiya ID FD SA PA and BFWP,V 3.7 and 45kW to 315kW 35nos
Total VFD
2.5MW 3MW 1MW 1MW 2.5MW 0.5MW 14MW 2MW
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The Madras Alunimum Co. Ltd., (Vedanta) ID and FD 132kW & 160kW 9+9 nos TNPL Power Plant - ID FD SA PA and BFWP
fuel feeder 2.2kw and 37 kw to 580kw ( 12 puls and 6 puls with Trafo)
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Khazakistan
Various
22kw-250KW
230
Karur
5.5kw-800KW
49
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Application: Co-generation power plant panel End Customer: Himatsingka Consultant: Avant Garde Location: Vacon Bangalore during inspection
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Application: Co-generation power plant panel End Customer: Himatsingka Consultant: Avant Garde Location: Himatsingka , Hassan
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Application:
Co-generation power plant panel ACB panels with Areva Relays End Customer: Himatsingka Consultant: Avant Garde Location: Himatsingka , Hassan Relays
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Application: 210MW Co-generation power plant panel End Customer: M/S Ind Bharat Customer: M/S Green sole Location: M/S Ind Bharat , Tuticorin
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Application: Customer:
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Application: Customer:
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Application: Crane End Customer: M/S IISCO ,Buhranpur Customer: M/s Mukund Ltd, Mumbai Consultant: Mecon Location: VACON Bangalore
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Application: Crane End Customer: M/S ISCO ,Buhranpur Customer: M/s Mukund Ltd, Mumbai Consultant: Macon Location: VACON Bangalore
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Application: Motor Generator set 2MW End Customer: M/S CPRI, Bangalore Customer: M/s KEC, Bangalore Location: VACON Bangalore
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Application: Motor Generator set 2MW End Customer: M/S Naval dockyard, Vizag Customer: M/s KEC, Bangalore Location: VACON Bangalore
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Application: Motor Generator set 2MW End Customer: M/S Naval dockyard, Vizag Customer: M/s KEC, Bangalore Location: VACON Bangalore
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Chain Drive conveyor 250KW M/S Vaizag Steel Plant VACON Bangalore
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CASE STORIES
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Why Vacon???
Flexible configuration of modules Use of NC engineering Input AC Chokes Strong reference in Cement industry mainly Kiln drives Good global reference of long conveyor Committed ON TIME delivery of 8 weeks Packaged solution-AC drives, Invertor Transformer & PLC
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System Configuration
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PANEL PICTURE
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System Info
Motors: 3x400kW/690V 2 Nos. at Head END 1 No at Tail END Conveyors: Distance between Head and Tail End- 4.05kM Speed of conveyor:3.5m/sec Material: Gypsum Drives: Vacon Hardware NXP0650 6- 12 Pulse 3 Nos.
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System Description
Pipe conveyor is being installed for transportation of raw materials (Gypsum) from Crusher House (Tail End) to Discharge bins/Silo at Head End The VFD system is for controlling the speed of pipe conveyors having 3 x 400kW Motors (2 nos. at head and 1 no. at tail end, 4.5km away from head end) Head End VFDs shall be on Master / Follower configuration connected with each other through Vacon System Bus network. Datas between PLC and Head end drives (1&2) are being exchanged thru Profibus network. VFDs in group mode shall receive command and reference thru Field bus (Profibus). Ethernet module of PLC transfers speed reference and run commands (with all interlocks) to and from Tail End thru Ethernet/OFC converter. Digital I/O module of PLC ensures Group/Individual mode operation and other safety interlocks. Crusher PLC at Tail End sends RUN command and speed reference to Tail End VFD. Tail END PLC receives those from VFD thru Profibus and in turn shares command and reference to Head End VFDs thru Ethernet.
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Fault Conditions:
Under any fault condition, (Transformer, Field devices, Pull cord, Zero Speed and Belt sway switches, Winding/Bearing temp of motors), audible alarms are generated at both ends (Head and Tail) and total system is stopped thus safety is ensured. ALL DRIVES ARE CONFIGURED IN DROOP MODE,WHICH IS AN OVER RIDING CONTROL INCASE PLC FAILS
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System Configuration
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System Configuration
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PANEL PICTURE
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System Info
Motors: BHEL make induction Motor 705Kw, 743A, 990rpm, 690V, 50Hz with inbuilt thermistors provided for each winding. Motor is equipped with external liquid cooling system Kiln: The kiln is 64 meter length, 4.15 meter dia with maximum Max Speed of Kiln:5 RPM 5rpm Capacity: 4200 TPD (Tones per Day Production) Inlet and outlet temperature respectively 900C and 1400C.
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System Info
Drive Details: 12 pulse NFE + INUs + BCU NFE:520*4 INU:1030*2 BCU:NXB105 Transformer:VOLTAMP Make 6.6kV/690V/1500KVA (Star & Delta). 3~/50 Hz transformer having Impedance Voltage HV1 LV1: 6.18% HV1 LV2: 6.18%
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System Info
Gear Box: The gear box and motor is 25:1 ratio. Here the gear box power is 571kw and the rpm details are following. Primary N1: 816 1360 Motor rpm: 272 Gear Box output: 10.8rpm Kiln RPM: 1 Max Kiln RPM with 990RPM motor:3.6RPM Secondary N2 : 1.58 - 52.63
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Why Vacon???
Flexible configuration of modules Reliable & robust Use of NC engineering Input AC Chokes Strong reference in Cement industry mainly Kiln drives Supplied by L&T, experts in cement solutions Supplied by L&T under their brand name LNTAC690
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